Ammunition articles with plastic components and method of making ammunition articles with plastic components

ABSTRACT

An ammunition article includes a molded plastic cartridge casing body having a first end and a second end, and a projectile attached to the first end of the cartridge casing body. The cartridge casing body is molded around at least a portion of the projectile. A molded plastic base for an ammunition article, a molded plastic blank cartridge, and a molded plastic cartridge casing body having a pronged web are also disclosed.

This application claims the benefit of U.S. Provisional Application No.60/116,232, filed Jan. 15, 1999.

FIELD OF THE INVENTION

The present invention relates to ammunition articles and methods ofmaking ammunition articles and, more particularly, to ammunitionarticles with plastic components such as cartridge casing bodies andbases, and methods of making ammunition articles with plasticcomponents.

BACKGROUND AND SUMMARY

Plastic cartridge casings have been known for many years but have failedto provide satisfactory ammunition that could be produced in commercialquantities with sufficient safety, ballistic, and handlingcharacteristics. The problems evidenced by all of the known methods ofproducing plastic or substantially plastic ammunition include thepossibility of the projectile being pushed into the cartridge casing,the bullet pull being too light such that the bullet can fall out, thebullet pull being insufficient to create enough chamber pressure, thebullet pull being too great causing excessive chamber pressure, thebullet pull not being uniform from round to round, portions of thecartridge casing breaking off upon firing of the projectile causingdamage or danger when subsequent rounds are fired or when the casingportions themselves become projectiles, and expense due to manufacturingtechniques or multiple material constructions. In the manufacture ofblanks using plastic cartridge cases, similar problems to those presentwith prior art cartridge cases for conventional ammunition exist, aswell as problems associated with portions of the cartridge casesbreaking off and becoming dangerous, high velocity plastic projectiles.

Certain of the foregoing problems are addressed in European PatentApplication 0 131 863, which discloses a plastic cartridge casing thatis provided with a ring or a plurality of rings or with a pronouncedradially inward taper to engage corresponding surfaces on the bullet sothat the bullet may be snapped into the casing. However, the techniqueof forming a cartridge casing and then snapping a bullet into the casingis time consuming in that it involves multiple steps, is manpower andequipment intensive in that different equipment is necessary to performvarious tasks in the manufacturing process, and still risks a less thanperfect fit between bullet and casing in that the casings are not customfit to each bullet. It is desirable to provide ammunition articleshaving plastic cartridge casing bodies, cartridge casings with plasticcartridge casing bodies, and plastic cartridge casing bodies that ensurea high-quality fit between the plastic cartridge casing body and theprojectile, and methods of manufacture for such articles that are simpleand require minimal manpower and equipment.

According to one aspect of the present invention, an ammunition articleis provided, the ammunition article including a molded plastic cartridgecasing body having a first end and a second end, and a projectileattached to the first end of the cartridge casing body. The cartridgecasing body is molded around at least a portion of the projectile.

According to another aspect of the present invention, an ammunitionarticle is provided, the ammunition article including a cartridge casingbody having a first end and a second end, a projectile attached to thefirst end of the cartridge casing body, and a single piece, moldedplastic base, the base being attached to the second end of the cartridgecasing body.

According to another aspect of the present invention, an ammunitionarticle is provided, the ammunition article including a molded plasticcartridge case body having a closed front end and a second end.

According to another aspect of the present invention, an ammunitionarticle is provided, the ammunition article including a molded plasticcartridge case body, the cartridge case body including a web dividing aninternal volume of the body to define a lower cavity for receiving apropellant and an upper cavity for receiving a projectile, the webincluding an upwardly extending prong for being received in acorresponding recess in a base of the projectile to fasten the body tothe projectile.

According to another aspect of the present invention, a method of makingan ammunition article includes the steps of molding plastic around atleast a portion of a projectile to form a plastic cartridge casing bodyhaving a first end to which the projectile is attached and a second end.

According to another aspect of the present invention, a method of makingan ammunition article includes the steps of molding plastic to form asingle piece, molded plastic base, and attaching the base to an end of acartridge casing body.

According to another aspect of the present invention, a method of makingan ammunition article includes the steps of molding plastic around acore pull to form a molded plastic cartridge case body having a closedfront end and a second end, and removing the core pull from thecartridge casing body.

According to another aspect of the present invention, a method of makingan ammunition article includes the steps of molding plastic to form amolded plastic cartridge case body, the cartridge case body including aweb dividing an internal volume of the body to define a lower cavity forreceiving a propellant and an upper cavity for receiving a projectile,the web including an upwardly extending prong, and causing the upwardlyextending prong to be received in a corresponding recess in a base ofthe projectile to fasten the body to the projectile.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention are well understoodby reading the following detailed description in conjunction with thedrawings in which like numerals indicate similar elements and in which:

FIG. 1 is a top perspective view of an ammunition article according to afirst embodiment of the present invention;

FIG. 2 is a bottom perspective view of an ammunition article accordingto the first embodiment of the present invention;

FIG. 3 is a side view of an ammunition article according to the firstembodiment of the present invention;

FIGS. 4A and 4B are side, cross-sectional views of an ammunition articleaccording to the first embodiment of the present invention;

FIG. 5 is a top perspective view of a cartridge casing body according tothe first embodiment of the present invention and illustrated withoutthe projectile;

FIG. 6 is a cross-sectional view of a portion of an ammunition articleaccording to the first embodiment of the present invention;

FIG. 7 is a cross-sectional view of an embodiment of a projectile foruse in connection with the ammunition article according to the firstembodiment of the present invention;

FIG. 8 is a cross-sectional view of another embodiment of a projectilefor use in connection with the ammunition article according to the firstembodiment of the present invention;

FIG. 9A is a cross-sectional view of a portion of an ammunition articleaccording to the first embodiment of the present invention;

FIGS. 9B and 9C are partial, top views of a portion of an ammunitionarticle according to the first embodiment of the present invention,showing possible forms of flanges;

FIG. 10 is a cross-sectional view of a portion of an embodiment of theammunition article according to the first embodiment of the presentinvention shown after firing;

FIG. 11 is a cross-sectional view of an embodiment of the ammunitionarticle according to the first embodiment of the present invention;

FIG. 12 is a cross-sectional view of a portion of an ammunition articleaccording to the first embodiment of the present invention;

FIG. 13A-14B are partially cross-sectional views of molding equipmentfor making an embodiment of a cartridge casing body for an ammunitionarticle according to the first embodiment of the present invention;

FIG. 15 is a cross-sectional view of an assembly step according to amethod for making an ammunition article according to the firstembodiment of the present invention;

FIG. 16 is an exploded view of an ammunition article according to asecond embodiment of the present invention;

FIG. 17 is an exploded, cross-sectional view of an ammunition articleaccording to the second embodiment of the present invention;

FIG. 18A is a front perspective view of a molded plastic base accordingto an embodiment of the ammunition article according to the secondembodiment of the present invention;

FIG. 18B is a side, cross-sectional view of a molded base according toan embodiment of the ammunition article;

FIG. 19 is a rear perspective view of a molded plastic base according toan embodiment of the ammunition article according to the secondembodiment of the present invention;

FIG. 20 is a rear perspective view of an embodiment of a cartridgecasing body for use with an embodiment of the ammunition articleaccording to the second embodiment of the present invention;

FIG. 21 is a partially cross-sectional view of molding equipment formaking a plastic base for an ammunition article according to the secondembodiment of the present invention;

FIG. 22 is a side view of an ammunition article according to a thirdembodiment of the present invention;

FIG. 23 is a partially cross-sectional view of molding equipment formaking an ammunition article according to the third embodiment of thepresent invention;

FIG. 24 is a front perspective view of a core pull for use in making anammunition article according to the third embodiment of the presentinvention;

FIG. 25 is a front end view of a core pull for use in making anammunition article according to the third embodiment of the presentinvention;

FIG. 26 is a side view of a core pull for use in making an ammunitionarticle according to the third embodiment of the present invention;

FIG. 27 is a side view of a core pull inserted in a partially brokenammunition article according to the third embodiment of the presentinvention;

FIG. 28 is a side, cross-sectional view of a portion of an ammunitionarticle according to a fourth embodiment of the present invention;

FIG. 29 is a side, cross-sectional view of a portion of an ammunitionarticle according to a fifth embodiment of the present invention; and

FIG. 30 is a side, cross-sectional view of a portion of an ammunitionarticle according to a sixth embodiment of the present invention.

DETAILED DESCRIPTION

An ammunition article 21 according to an embodiment of the presentinvention is shown in FIGS. 1-3. As seen in cross-section in FIGS. 4Aand 4B, the ammunition article 21 includes a molded plastic cartridgecasing body 23 having a first end 25 and a second end 27. A projectile29 is attached to the first end 25 of the cartridge casing body 23. Thecartridge casing body 23 is a molded plastic part, and is formed byplastic being molded around at least a portion 31 of the projectile 29.As discussed with reference to FIG. 29, if desired or necessary, thecartridge casing body may be formed by plastic being molded to conformonly with a bottom of a projectile, with a plastic protrusion extendinginto a cavity in the bottom of the projectile. The projectile 29 ispreferably any one of the wide variety of well-known projectiles butmay, if desired or necessary, include one or more features useful inconnection with the present invention.

As seen in FIG. 5 (showing the cartridge casing body with the projectileremoved for illustration) the cartridge casing body 23 preferablyincludes an interior volume 33 including a first interior portion 35defined by the portion 31 of the projectile 29 and a second interiorportion 37 having a smaller diameter than the first interior portion andbeing separated from the first interior portion by a shoulder 39. Asseen in FIGS. 5 and 6, the shoulder 39 is preferably of sufficient sizeto prevent axial movement of the projectile 29 into the second interiorportion 37. The second interior volume 37 is preferably formed by a corepull (FIGS. 13A-14B) used in a cartridge casing body molding operationwherein a leading end of the core pull preferably abuts against the base40 of the projectile 29. As seen in FIG. 7, the base 40 of theprojectile may be flat or, as seen in FIG. 8, contoured, such as bybeing concave. The base 40 may be contoured to any shape desired ornecessary, such as concave, convex, a combination of concave or convex,have straight portions, or curved portions, depending upon factors suchas the ballistic requirements of the projectile.

The projectile 29 is preferably attached to the cartridge casing body 23by one or more attachment arrangements 41 directed to preventing axialmovement of the projectile relative to the cartridge casing body priorto firing, such as during storage or shipment, and during accidents suchas dropping of the ammunition article. Depending upon the type ofammunition article being manufactured, desirable characteristics of theattachment arrangement 41 may include the ability to provide sufficientbullet pull to permit creation of neither too much nor too littlechamber pressure during firing of the projectile, ensuring uniformbullet pull from round to round, and avoiding causing portions of thecartridge casing body to break off when the ammunition article is fired.Suitable attachment arrangements 41 include a heat bond, an adhesivebond, and a weld, such as an ultrasonic weld, between the portion 31 ofthe projectile and the cartridge casing body 23. The attachmentarrangement may be a mechanical attachment arrangement wherein portionsof the cartridge casing body 23 and the portion 31 of the projectile 29are caused to interconnect. The attachment arrangement may, of course,be nothing more than a metal to plastic bond between the portion 31 ofthe projectile 29 and the cartridge casing body 23 created during themolding operation.

A form of attachment arrangement 41, seen in detail in FIG. 9A, includesa flange 41′ on the cartridge casing body 23 extending into a recess 43in the projectile 29. Optimal dimensions for the flange 41′ will varydepending upon the specific type of ammunition article 21 to be made.When the cartridge casing body 23 is made of a modified ZYTEL resin,available from E.I. DuPont De Nemours Co., a modified 612 nylon resin,modified to increase elastic response, and the ammunition article isso-called “38 Special” type ammunition, a desirable dimension for anannular flange 41′ is 0.009″ thick by 0.020″ wide, i.e., the recess 43is an annular recess in the projectile 29 that is about 0/009″ thick by0.020″ wide. The flange 41′ and the recess 43 are not limited to beingannular, and can be any of a variety of shapes and sizes, such as pinsand grooves, detents and detent receiving recesses, helixes, such asscrew threads, or any other suitable mechanically interconnectablestructure sufficient to retain the projectile 29 in position in thecartridge casing body 23. By proper selection of materials and flange41′ and recess 43 size, it is possible to design to a very exact degreefeatures of the ammunition article 21 such as bullet pull. As seen inFIGS. 9B and 9C, the flange 41′ need not be continuous around the entirecircumference of the projectile, such as in the embodiment shown in FIG.5, but may be in the form of multiple, discontinuous or interruptedforms. The shape of the flange 41′ may be any suitable shape, such as acone, a pyramid, a half-sphere, a half circular cylinder, a cube, orother geometrical form.

As seen in FIG. 10, the flange 41′, when provided, is preferably sizedsuch that, and the cartridge casing body 23 is preferably made of aplastic material suitable for its specific intended application suchthat, upon firing of the projectile 29, the flange 41′ breaks off fromthe rest of the body 23 and is carried off with the projectile, withoutalso causing other portions of the body 23 to break off. If desired ornecessary, multiple flanges 41 and recesses 43 can be arranged along alength of the cartridge casing body 23 and the portion 31 of theprojectile 29. It will be understood that an ammunition article 21 witha flange 41′ is just one embodiment of the present invention, and thatthe flange may be omitted in favor of one or more alternative attachmentarrangements, such as metal-plastic bonding from the molding operation,interference fit, heat bonding, adhesive, or ultrasonic welding, as seenin FIG. 11.

The ammunition article 21 preferably also includes a base 45 attached tothe second end 27 of the cartridge casing body 23. One suitable materialfor the cartridge casing body 23 is a modified ZYTEL resin, availablefrom E.I. DuPont De Nemours Co., a modified 612 nylon resin, modified toincrease elastic response. In embodiments of the present inventionwherein a molded cartridge casing body may be provided, a suitablecartridge casing body may also be made of a moldable material that formspart of the propellant pack, i.e., a moldable propellant, or otherwiseis itself combustible or consumable by a propellant such as a powderignition. The base 45 may be made of any suitable conventional material,for example, a metal material such as brass. According to one embodimentof the present invention, the base 45 is made of a plastic material, andis preferably molded out of a long fiber reinforced nylon material toprovide great stiffness, high compressive strength, and minimal coldflow, although other well known materials may be used for the base. Asdesired or necessary, the base may be a metal base, such as a brassbase, or a plastic material base, a ceramic base, a composite base, acombination of plastic, composite, or ceramic, or may incorporate thecomposite reinforced ceramic technology disclosed in U.S. patentapplication Ser. No. 08/590,621, which is expressly incorporated byreference. If desired or necessary, the base 45 and the cartridge casingbody 23 can be made of the same material. For at least someapplications, the cartridge casing body 23 is preferably somewhat moreflexible than the base 45 to facilitate creation of a gas seal with thechamber, but fracture properties are preferably such as to facilitatebreaking off of a flange 41′ (if provided) relatively cleanly from therest of the cartridge casing body without causing other parts of thecartridge casing body to break off and follow the projectile 29 duringfiring. Preferably, the base 45 is sufficiently sturdy to be reusable,even when it may be necessary to replace the cartridge casing body 23after each use.

The base 45 is attached to the cartridge casing body 23 by any suitableattachment arrangement, or combination of attachment arrangements. Asseen in FIG. 12, the base 45 may be attached to the cartridge casingbody 23 by a suitable attachment arrangement 47, such as by amechanically interconnecting structure or otherwise. Suitable attachmentarrangements 47 may include, for example, screw threads, a tongue andgroove arrangement, flanges or pins and grooves, detent and detentreceiving recesses, an interference fit, a heat bond, an adhesive, or anultrasonic weld, or a combination of these attachment arrangements.

As seen in FIG. 4B, the ammunition article 21 preferably includes apropellant charge P inside the cartridge casing body 23. A variety ofpropellant charge types are well known and, for purposes of the presentapplication and except where otherwise indicated, can be considered tobroadly include all suitable types of charges, such as those that areconventionally thought of as propellant charges and those that areconventionally considered to be explosive charges, such as black powdercharges or charges such as PYRODEX, a smokeless black powder substituteavailable from Hodgdon Powder Co., Inc., Shawnee Mission, Kans.Depending upon the type of ammunition article 21, the ammunition articlemay include some means for igniting the propellant, such as a primer 49(FIG. 4B) for igniting the propellant, or an electronic ignition 49′ forigniting the propellant (shown schematically in FIG. 4A), or means forigniting the propellant may be partially or completely external to theammunition article.

As seen in FIG. 13A, the cartridge casing body 23 is preferably made bymolding plastic around at least the portion 31 of the projectile 29 toform the plastic cartridge casing body having the first end 25 to whichthe projectile is attached and a second end 27. Numerous plastic moldingtechniques are well known and are suitable for use in connection withthe present application. The plastic is preferably molded around a corepull 51 such that the core pull and the portion 31 of the projectile 29define the interior volume 33 of the plastic cartridge casing body 23. Aleading end 52 of the core pull 51 preferably abuts against the base 40of the projectile 29. After molding, the core pull 51 is removed fromthe plastic cartridge casing body 23. Preferably, the core pull 51 has asmaller diameter than the portion 31 of the projectile such that theinterior volume 33 of the cartridge casing body 23 includes the firstinterior portion 35 defined by the portion of the projectile and asecond interior portion 37 having a smaller diameter than the firstinterior portion and being separated from the first interior portion bythe shoulder 39. The shoulder 39 is preferably of sufficient size toprevent axial movement of the projectile 29 into the second interiorportion 37.

If desired or necessary, one or more attachment arrangements above andbeyond the metal-plastic bond developed upon molding the plastic of theplastic cartridge casing body 23 around the portion 31 of the projectile29 may be provided. The attachment arrangement 41 can be provided by,for example, heat bonding the projectile to the cartridge casing body,by adhesive bonding of the projectile to the cartridge casing body, orultrasonic welding of the cartridge casing body to the projectile. Theattachment arrangement may be provided by providing one or more recesses43 in the portion 31 of the projectile 29 such that, when the plastic ismolded around the portion of the projectile, the plastic enters therecesses and forms what is referred to herein as a flange 41′ on thecartridge casing body 23, the flange 41′ extending into the recess.

As seen in FIGS. 13A and 13B, the molding operation is preferablyperformed in a mold 53 (showing a half mold and not showing another halfof the mold which is preferably symmetrical to the illustrated halfmold). The mold 53 preferably includes a cavity 55 in which the corepull 51 is axially movable to a position in which the leading end of thecore pull preferably abuts against the base 40 of the projectile 29. Asseen in FIG. 13A, a front end 57 of the projectile 29 is preferablypositioned against a mold element 59 corresponding in shape to the frontend of the projectile, and which ensures proper axial positioning of theprojectile relative to walls of the cavity 55. The mold element 59 maybe integral with the mold 53, or may be a separate part that may bemovable, as desired or necessary. An alternative form of mold 53″ isshown in FIG. 13C, wherein a stationary or movable element 59″ issubstituted for the mold element 59, and receives a front end of theprojectile for axial positioning of the projectile 29, and separablemold halves close around a rear portion of the projectile to define,with the projectile and a pull 51, walls of a cavity 55″ in which aplastic cartridge casing body is to be formed.

Another form of mold 53′ is shown in FIGS. 14A and 14B and, instead oftwo identical or similar mold halves, such as are used in the embodimentof the method shown in FIGS. 13A and 13B, as seen in FIG. 14A, the mold53′ preferably includes an end 53 a having a portion 59′ in which thefront end 57 of the projectile 29 is received and which positions theprojectile relative to walls 55′ of another end 53 b of the mold inwhich a core pull 51′ is provided. The core pull 51′ is preferablyaxially movable relative to the end 53 b. If desired or necessary, themold end 53 b may include two separable halves to facilitate removal ofthe cartridge casing body 23 and the projectile 29 after forming.

Regardless of the mold type used, and as discussed with reference toFIG. 13A, plastic is provided to the cavity 55 to fill voids between thewalls of the cavity 55 and the walls of the portion 31 of theprojectile, including any exposed portions of the base 40 of theprojectile, and the core pull 51 to form the cartridge casing body 23.If one or more recesses 43 are provided in the projectile 29,corresponding flanges 41′ are formed when the plastic fills therecesses. Attachment arrangements 41 such as heat bonds, adhesive bonds,and ultrasonic welds may be provided while the projectile 29 and thecartridge casing body 23 reside in the cavity 55, or after removal ofthe cartridge casing body and the projectile from the cavity, as desiredor necessary. Techniques for providing attachment arrangements 41 arewell known and will not be further described here. When the cartridgecasing body 23 is molded, the core pull 51 is axially drawn from thesecond interior portion 37 of the cartridge casing body.

As seen in FIG. 15, the propellant charge P, such as gunpowder or otherpropellant, is preferably provided inside of the cartridge casing body23, generally in the second interior portion 37 of the cartridge casingbody, and the base 45 is preferably attached to the second end 27 of thecartridge casing body, preferably following removal of the cartridgecasing body and the projectile 29 from the mold 53. If provided, anignition device such as a primer (FIG. 4B) or an electronic ignition(FIG. 4A) is also provided, or, depending upon the nature of theignition device, partially provided. If desired or necessary, it is, ofcourse, possible to construct a mold and core arrangement to permitproviding the charge P and attachment of the base 45 and primer whilethe cartridge casing body 23 and the projectile 29 continue to reside inthe mold 53.

The base 45 may be a metal, such as brass, base, or may be plastic,composite, ceramic, or a combination of materials. A plastic orcomposite base 45 is preferably molded separately from the moldingoperation in which the cartridge casing body 23 is molded, beforeattachment to the cartridge casing body. The base 45 may be attached tothe cartridge casing body 23 by any suitable attachment arrangementtechnique, such as through a mechanical attachment whereininterconnecting components of the base and the cartridge casing body arefitted together, or by any other suitable technique or combination oftechniques. The base 45 may, for example, be attached to the cartridgecasing body 23 by an attachment arrangement involving the screwingtogether of threads on the base with threads on the cartridge casingbody. The base 45 may be attached to the cartridge casing body 23 by anattachment arrangement technique involving connecting a tongue andgroove arrangement between attachable portions of the base and thecartridge casing body. The base 45 may be attached to the cartridgecasing body 23 by an attachment arrangement technique involving formingan interference fit between the cartridge casing body and the base. Thebase 45 may be attached to the cartridge casing body 23 by an attachmentarrangement technique involving adhesive joining. The base 45 may beattached to the cartridge casing body 23 by an attachment arrangementtechnique involving heat bonding. The base 45 may be attached to thecartridge casing body 23 by an attachment arrangement techniqueinvolving ultrasonic welding.

Another embodiment of an ammunition article 121 according to the presentinvention is shown in an exploded view in FIG. 16 but, when assembled,can appear substantially the same as the ammunition article 21illustrated in FIGS. 1-3. As seen in FIG. 17, the ammunition article 121includes a cartridge casing body 123 having a first end 125 and a secondend 127. A projectile 129 is attached to the first end 125 of thecartridge casing body 123. A base 131, seen in FIGS. 18A-19, ispreferably formed as a single piece of molded plastic, or from aceramic, a composite, or a combination of plastic, composite, orceramic, such as, for example, by starting with a ceramic liner 1311 andmolding a composite or plastic material 131 m over the ceramic liner, asseen in FIG. 18B. The base 131 may also incorporate the compositereinforced ceramic technology disclosed in U.S. patent application Ser.No. 08/590,621, which is hereby expressly incorporated by reference. Asseen in FIG. 17, the base 131 is attached to the second end of thecartridge casing body. In this embodiment, the cartridge casing body 123may be a plastic cartridge casing body, such as the plastic cartridgecasing body described in connection with FIGS. 1-15, or a metalliccartridge casing body, such as a brass body in which a projectile isinstalled, as seen in FIG. 20, or which is for a blank cartridge, or asuitable ceramic, composite, or other desired material. The cartridgecasing body 123 may also be made of a moldable material that forms partof the propellant pack, i.e., a moldable propellant, or otherwise isitself combustible or consumable by a propellant such as a powderignition.

A propellant charge is preferably provided inside the cartridge casingbody 123 and, as seen in FIG. 17, a device for igniting the propellant,such as a primer 133 or an electronic ignition may be provided, orpartially provided, for igniting the propellant. Although the base 131is a plastic base, the base is preferably made of a sufficiently sturdymaterial to be reusable although the cartridge casing body 123 may bereplaceable. The base 131 is attached to the cartridge casing body 123by any suitable attachment arrangement 135. The attachment arrangement135 may, for example, be a mechanical attachment arrangement whereinportions of the base 131 and the cartridge casing body 123 interconnectwith each other. Suitable attachment arrangements 135 include screwthread arrangements wherein the base 131 is attached to the cartridgecasing body 123 by screw threads, tongue and groove arrangements, aninterference fit the cartridge casing body, adhesive, a heat bond, andan ultrasonic weld.

The ammunition article 121 is preferably made according to a method asseen in FIG. 21 wherein plastic is molded in a mold 137 around one ormore cores 139 to form the single piece, molded plastic base 131. Themold 137 may have two, substantially symmetrical halves, as seen in FIG.21, that separate in a direction transverse to a longitudinal axis ofthe base 131, the mold may have two parts that separate in a directionof a longitudinal axis of the base, or the mold may have a singlecomponent, with the core 139 closing an end of the single component moldand one or both of the core and the single component mold being movableto permit removal of the base. If desired or necessary, the cartridgecasing body or an ignition device or some component of an ammunitionarticle may form part or all of a core around which the base 131 ismolded. As seen in FIGS. 16 and 17, preferably after molding, the base131 is attached to the second end 127 of the cartridge casing body 123using a suitable attachment arrangement 135. The cartridge casing body123 may be a molded plastic cartridge casing body, such as the bodydescribed with reference to FIGS. 1-15, which is preferably formed in aseparate operation from the molding of the base 131, or a metalliccartridge casing body, such as the body shown in FIG. 20. Preferably,before attachment of the base 131 and the cartridge casing body 123, apropellant is provided in the cartridge casing body. A device forigniting the propellant may be provided or partially provided, such as aprimer 133 or an electronic ignition, and may be attached or partiallyattached to the base 131 depending upon the nature of the device.

Another embodiment of an ammunition article 221 according to the presentinvention is shown in FIG. 22. The ammunition article 221 isparticularly well-suited for use as a blank cartridge. The ammunitionarticle 221 includes a molded plastic cartridge case body 223 having aclosed front end 225 and a second end 227. Although the ammunitionarticle 221 is illustrated as having a convex front end 225, it will beappreciated that the front end can be any shape desired or necessary,such as flat, convex, or whatever shape yields desired characteristics.

As seen in FIG. 23, the ammunition article 221 is preferably molded in amold 229 around a core pull 231. The core pull 231 and the mold 229 arepreferably shaped such that the closed front end 225 preferably includeswalls that reduce in thickness toward an axial center 233 of the closedfront end to facilitate causing the ammunition article to break at thetip and minimize the potential for portions of the wall becomingprojectiles. Moreover, the closed front end 225 preferably includes atleast one, preferably a plurality of stress concentrators 235 forcausing preferential tearing of the closed front end at the stressconcentrators such that, upon firing, the front end will tend to splitopen at the axial tip at the center 233 and permit expansion of acharge, preferably a charge consisting of an explosive charge, such asblack powder or PYRODEX, a smokeless black powder substitute availablefrom Hodgdon Powder Co., Inc., Shawnee Mission, Kans. If desired ornecessary, another propellant charge may be used.

As seen in FIG. 24-26, the core pull 231 preferably has raised portions237 for forming the stress concentrators 235. The raised portions 237are preferably in the form of intersecting lines that intersect at thetip 239 of the core pull 231 such that the resulting shape of the stressconcentrators 235 on the interior wall of the front portion 225 of thecartridge casing body 223 will be such that the cartridge casing bodywill split open along the stress concentrators at the center 233 andalong the length of the stress concentrators, reducing the possibilityof portions of the cartridge casing body becoming projectiles uponexpansion of a powder charge. If desired or necessary, stressconcentrators can be provided on an exterior surface of the cartridgecasing body 223 in addition to or instead of the stress concentrators235 on the interior surface of the front portion 225, preferably byproviding appropriately shaped raised portions on the mold 229.

As with the cartridge casing body 23, a base 241 (shown in phantom inFIG. 22) like the base 45 is preferably attached to the cartridge casingbody 223 by one or more of the same attachment arrangements, and apropellant (not shown) and a powder charge ignition device (not shown)are preferably also provided. The base may be a reusable base, and thecartridge casing body 223 is preferably replaceable on the base.

As seen in FIGS. 23 and 27, the cartridge casing body 223 is preferablyformed by molding plastic around the core pull 231 to form the moldedplastic cartridge case body 223 having a closed front end 225 and asecond end 227. The core pull 231 is removed from the cartridge casingbody 223 after the plastic is molded around the core pull. The mold 229is preferably a two-piece mold (one piece of which is shown in FIG. 23)that separates along a plane extending through a longitudinal axis ofthe cartridge casing body, and at least one of the mold and the corepull 231 is movable relative to the other such that the core pull can beremoved along the longitudinal axis of the cartridge casing body.

Yet another embodiment of an ammunition article 321 is shown in anexploded view in FIG. 28. The ammunition article 321 includes a moldedplastic cartridge case body 323. The cartridge case body 323 includes aweb 325 dividing an internal volume of the body to define a lower cavity327 for receiving a propellant and an upper cavity 329 for receiving aprojectile 331. The web 325 includes an upwardly extending prong 333 forbeing received in a corresponding recess 335 in a base 337 of theprojectile 331 to fasten the cartridge casing body 323 to theprojectile. The prong 333 may be attached in the recess 335 by anysuitable attachment arrangement and attachment technique, such as by aninterference fit, by interlocking structures on the prong and therecess,.by an adhesive, by heat bonding, and by ultrasonic welding. Thecartridge casing body 323 may, of course, be molded around theprojectile 331 in a manner similar to the manner in which the cartridgecasing body 23 is molded around the projectile 29, except that a corepull would not extend all the way to a base of the projectile. The prong333 may be formed by causing plastic to enter the recess 333 during themolding operation. Alternatively, the cartridge casing body 323 may beformed in a separate molding operation and thereafter attached to theprojectile 331 such that the prong 333 is caused to enter the recess335. A base (not shown) may be attached by a suitable attachmentarrangement in the same way that the base 45 is attached to thecartridge casing body 23, and a propellant charge (not shown) and apropellant ignition device (not shown) may be provided in the same wasas with the ammunition article 21. U.S. Pat. No. 5,033,386 and U.S. Pat.No. 5,151,555 disclose plastic cartridge cases having a web extendingacross a body of the cartridge cases and are hereby expresslyincorporated by reference.

FIG. 29 discloses yet another embodiment of an ammunition article 321′including a plastic cartridge casing body 323′. The body 323′ is moldedto conform with a bottom end 325′ of the projectile in which a recess327′ is provided such that a protrusion 329′ is molded in the recessand, preferably, the walls of the body do not extend up the sides of theprojectile. This embodiment of the ammunition article 321′ facilitatesuse of a combustible cartridge casing body 323′, such as where thecartridge casing body itself forms part of the propellant pack. Wherethe cartridge casing body 323′ is intended to be part of the propellantpack, the base is preferably adapted to expand during firing to form agas seal. As desired or necessary, the base may be a metal base, such asa brass base, or a plastic material base, a ceramic base, a compositebase, a combination of plastic, composite, or ceramic, or mayincorporate the composite reinforced ceramic technology disclosed inU.S. patent application Ser. No. 08/590,621, which is expresslyincorporated by reference.

Yet another embodiment of an ammunition article 421 according to thepresent invention comprises a projectile 423 having cannelure contours425 and a molded cartridge casing body 427 molded around at least aportion of the projectile such that a portion 429 of a wall 431 of thecartridge casing body follows the cannelure contours of the projectile.The portion 429 of the wall 431 preferably has a substantially constantthickness such that, where the projectile is recessed, the portion ofthe wall is also recessed.

The foregoing embodiments of the present invention are all believed tobe useful for use with all types of cartridges or blanks, regardless ofshape. For example, in all of the embodiments, the cartridge casing bodymay be, for example, cylindrical, bottle-shaped, or have other suitableshapes as desired or necessary.

While this invention has been illustrated and described in accordancewith a preferred embodiment, it is recognized that variations andchanges may be made therein without departing from the invention as setforth in the claims.

1. An ammunition article, comprising: a molded plastic cartridge casingbody having a first end and a second end; and a projectile attached tothe first end of the cartridge casing body, wherein the cartridge casingbody is molded around at least a portion of the projectile.
 2. Theammunition article as set forth in claim 1, wherein the cartridge casingbody includes an interior volume including a first interior portiondefined by the portion of the projectile and a second interior portionhaving a smaller diameter than the first interior portion and beingseparated from the first interior portion by a shoulder, the shoulderbeing of sufficient size to prevent axial movement of the projectileinto the second interior portion.
 3. The ammunition article as set forthin claim 1, wherein the projectile is attached to the cartridge casingbody by a heat bond of sufficient strength to prevent axial movement ofthe projectile relative to the cartridge casing body prior to firing. 4.The ammunition article as set forth in claim 1, wherein the projectileis attached to the cartridge casing body by an adhesive bond ofsufficient strength to prevent axial movement of the projectile relativeto the cartridge casing body prior to firing.
 5. The ammunition articleas set forth in claim 1, wherein the projectile is attached to thecartridge casing body by a flange on the cartridge casing body extendinginto a recess in the projectile.
 6. The ammunition article as set forthin claim 1, further comprising a base attached to the second end of thecartridge casing body.
 7. The ammunition article as set forth in claim6, further comprising a propellant charge inside the cartridge casingbody.
 8. The ammunition article as set forth in claim 7, furthercomprising a primer for igniting the propellant.
 9. The ammunitionarticle as set forth in claim 7, further comprising an electronicignition for igniting the propellant.
 10. The ammunition article as setforth in claim 6, wherein the base is reusable and the cartridge casingbody is replaceable.
 11. The ammunition article as set forth in claim 6,wherein the base is a molded plastic base.
 12. The ammunition article asset forth in claim 6, wherein the base is mechanically attached to thecartridge casing body.
 13. The ammunition article as set forth in claim12, wherein the base is attached to the cartridge casing body by screwthreads.
 14. The ammunition article as set forth in claim 12, whereinthe base is attached to the cartridge casing body by a tongue and groovearrangement.
 15. The ammunition article as set forth in claim 12,wherein the base is attached to the cartridge casing body by aninterference fit.
 16. The ammunition article as set forth in claim 6,wherein the base is attached to the cartridge casing body by adhesive.17. The ammunition article as set forth in claim 6, wherein the base isattached to the cartridge casing body by a heat bond.
 18. The ammunitionarticle as set forth in claim 6, wherein the base is attached to thecartridge casing body by an ultrasonic weld.
 19. The ammunition articleas set forth in claim 1, wherein the cartridge casing body is formed ofa combustible material.
 20. The ammunition article as set forth in claim1, wherein a wall thickness of the cartridge casing body followscannelure contours of the projectile.
 21. An ammunition article,comprising: a cartridge casing body having a first end and a second end;a projectile attached to the first end of the cartridge casing body; anda single piece, molded plastic base, the base being attached to thesecond end of the cartridge casing body.
 22. The ammunition article asset forth in claim 21, wherein the cartridge casing body is made ofmetal.
 23. The ammunition article as set forth in claim 21, wherein thecartridge casing body is made of plastic.
 24. The ammunition article asset forth in claim 21, further comprising a propellant charge inside thecartridge casing body.
 25. The ammunition article as set forth in claim24, further comprising a primer for igniting the propellant.
 26. Theammunition article as set forth in claim 24, further comprising anelectronic ignition for igniting the propellant.
 27. The ammunitionarticle as set forth in claim 21, wherein the base is reusable and thecartridge casing body is replaceable.
 28. The ammunition article as setforth in claim 21, wherein the base is mechanically attached to thecartridge casing body.
 29. The ammunition article as set forth in claim21, wherein the base is attached to the cartridge casing body by screwthreads.
 30. The ammunition article as set forth in claim 21, whereinthe base is attached to the cartridge casing body by a tongue and groovearrangement.
 31. The ammunition article as set forth in claim 21,wherein the base is attached to the cartridge casing body by aninterference fit.
 32. The ammunition article as set forth in claim 21,wherein the base is attached to the cartridge casing body by adhesive.33. The ammunition article as set forth in claim 21, wherein the base isattached to the cartridge casing body by a heat bond.
 34. The ammunitionarticle as set forth in claim 21, wherein the base is attached to thecartridge casing body by an ultrasonic weld.
 35. The ammunition articleas set forth in claim 21, wherein the cartridge casing body is formed ofa composite material.
 36. The ammunition article as set forth in claim21, wherein the cartridge casing body is formed of a combustible moldedmaterial.
 37. An ammunition article, comprising: a molded plasticcartridge case body having a closed front end and a second end.
 38. Theammunition article as set forth in claim 37, wherein the closed frontend includes walls that reduce in thickness toward an axial center ofthe closed front end.
 39. The ammunition article as set forth in claim37, wherein the closed front end includes at least one stressconcentrator for causing preferential tearing of the closed front end atthe at least one stress concentrator.
 40. The ammunition article as setforth in claim 37, further comprising a base attached to the second endof the cartridge casing body.
 41. The ammunition article as set forth inclaim 40, further comprising a propellant charge inside the cartridgecasing body.
 42. The ammunition article as set forth in claim 41,further comprising a primer for igniting the propellant.
 43. Theammunition article as set forth in claim 41, further comprising anelectronic ignition for igniting the propellant.
 44. The ammunitionarticle as set forth in claim 40, wherein the base is reusable and thecartridge casing body is replaceable.
 45. The ammunition article as setforth in claim 40, wherein the base is a molded plastic base.
 46. Theammunition article as set forth in claim 40, wherein the base ismechanically attached to the cartridge casing body.
 47. The ammunitionarticle as set forth in claim 46, wherein the base is attached to thecartridge casing body by screw threads.
 48. The ammunition article asset forth in claim 46, wherein the base is attached to the cartridgecasing body by a tongue and groove arrangement.
 49. The ammunitionarticle as set forth in claim 46, wherein the base is attached to thecartridge casing body by an interference fit.
 50. The ammunition articleas set forth in claim 40, wherein the base is attached to the cartridgecasing body by adhesive.
 51. The ammunition article as set forth inclaim 40, wherein the base is attached to the cartridge casing body by aheat bond.
 52. The ammunition article as set forth in claim 40, whereinthe base is attached to the cartridge casing body by an ultrasonic weld.53. An ammunition article, comprising: a molded plastic cartridge casebody, the cartridge case body including a web dividing an internalvolume of the body to define a lower cavity for receiving a propellantand an upper cavity for receiving a projectile, the web including anupwardly extending prong for being received in a corresponding recess ina base of the projectile to fasten the body to the projectile.
 54. Theammunition article as set forth in claim 53, wherein the prong isattached in the recess by an interference fit.
 55. The ammunitionarticle as set forth in claim 53, wherein the prong is attached in therecess by interlocking structures on the prong and the recess.
 56. Theammunition article as set forth in claim 53, wherein the prong isattached in the recess by an adhesive.
 57. The ammunition article as setforth in claim 53, wherein the prong is attached in the recess by heatbonding.
 58. The ammunition article as set forth in claim 53, whereinthe prong is attached in the recess by ultrasonic welding.
 59. A methodof making an ammunition article, comprising the steps of: moldingplastic around at least a portion of a projectile to form a plasticcartridge casing body having a first end to which the projectile isattached and a second end.
 60. The method as set forth in claim 59,wherein the plastic is molded around a core pull such that the core pulland the portion of the projectile define an interior volume of theplastic cartridge casing body, the method comprising the further step ofremoving the core pull from the plastic cartridge casing body.
 61. Themethod as set forth in claim 60, wherein the core pull has a smallerdiameter than the portion of the projectile such that the interiorvolume of the cartridge casing body includes a first interior portiondefined by the portion of the projectile and a second interior portionhaving a smaller diameter than the first interior portion and beingseparated from the first interior portion by a shoulder, the shoulderbeing of sufficient size to prevent axial movement of the projectileinto the second interior portion.
 62. The method as set forth in claim59, comprising the further step of heat bonding the projectile to thecartridge casing body.
 63. The method as set forth in claim 59,comprising the further step of adhesive bonding the projectile to thecartridge casing body.
 64. The method as set forth in claim 59, whereinthe plastic is molded around the portion of the projectile such that theplastic enters a recess in the portion of the projectile and forms aflange on the cartridge casing body extending into the recess.
 65. Themethod as set forth in claim 59, comprising the further step ofattaching a base to the second end of the cartridge casing body.
 66. Themethod as set forth in claim 65, comprising the further step ofproviding a propellant charge inside the cartridge casing body.
 67. Themethod as set forth in claim 66, comprising the further step ofproviding a primer for igniting the propellant.
 68. The method as setforth in claim 66, comprising the further step of providing anelectronic ignition for igniting the propellant.
 69. The method as setforth in claim 65, comprising the further step of molding the base fromplastic.
 70. The method as set forth in claim 69, wherein the base ismolded from plastic prior to attaching the base to the cartridge casingbody.
 71. The method as set forth in claim 65, wherein the base ismechanically attached to the cartridge casing body.
 72. The method asset forth in claim 71, wherein the base is attached to the cartridgecasing body by screwing threads on the base together with threads on thecartridge casing body.
 73. The method as set forth in claim 71, whereinthe base is attached to the cartridge casing body by connecting a tongueand groove arrangement between attachable portions of the base and thecartridge casing body.
 74. The method as set forth in claim 71, whereinthe base is attached to the cartridge casing body by an interferencefit.
 75. The method as set forth in claim 65, wherein the base isattached to the cartridge casing body by adhesive joining.
 76. Themethod as set forth in claim 65, wherein the base is attached to thecartridge casing body by heat bonding.
 77. The method as set forth inclaim 65, wherein the base is attached to the cartridge casing body byultrasonic welding.
 78. A method of making an ammunition article,comprising the steps of: molding plastic to form a single piece, moldedplastic base; and attaching the base to an end of a cartridge casingbody.
 79. The method as set forth in claim 78, comprising the furtherstep of molding plastic to form the cartridge casing body.
 80. Themethod as set forth in claim 78, comprising the further step ofproviding a propellant charge inside the cartridge casing body.
 81. Themethod as set forth in claim 80, comprising the further step ofproviding a primer for igniting the propellant.
 82. The method as setforth in claim 80, comprising the further step of providing anelectronic ignition for igniting the propellant.
 83. The method as setforth in claim 78, wherein the base is mechanically attached to thecartridge casing body.
 84. The method as set forth in claim 83, whereinthe base is attached to the cartridge casing body by screwing threads onthe base together with threads on the cartridge casing body.
 85. Themethod as set forth in claim 83, wherein the base is attached to thecartridge casing body by connecting a tongue and groove arrangementbetween attachable portions of the base and the cartridge casing body.86. The method as set forth in claim 83, wherein the base is attached tothe cartridge casing body by an interference fit.
 87. The method as setforth in claim 78, wherein the base is attached to the cartridge casingbody by adhesive joining.
 88. The method as set forth in claim 78,wherein the base is attached to the cartridge casing body by heatbonding.
 89. The method as set forth in claim 78, wherein the base isattached to the cartridge casing body by ultrasonic welding.
 90. Amethod of making an ammunition article, comprising the steps of: moldingplastic around a core pull to form a molded plastic cartridge case bodyhaving a closed front end and a second end; and removing the core pullfrom the cartridge casing body.
 91. The method as set forth in claim 90,wherein the plastic is molded such that closed front end includes wallsthat reduce in thickness toward an axial center of the closed front end.92. The method as set forth in claim 90, wherein the plastic is moldedsuch that the closed front end includes at least one stress concentratorfor causing preferential tearing of the closed front end at the at leastone stress concentrator.
 93. The method as set forth in claim 90,comprising the further step of attaching a base to the second end of thecartridge casing body.
 94. The method as set forth in claim 90,comprising the further step of providing a propellant charge inside thecartridge casing body.
 95. The method as set forth in claim 94,comprising the further step of providing a primer for igniting thepropellant.
 96. The method as set forth in claim 94, comprising thefurther step of providing an electronic ignition for igniting thepropellant.
 97. The method as set forth in claim 93, comprising thefurther step of molding the base from plastic.
 98. The method as setforth in claim 97, wherein the base is molded from plastic prior toattaching the base to the cartridge casing body.
 99. The method as setforth in claim 93, wherein the base is mechanically attached to thecartridge casing body.
 100. The method as set forth in claim 99, whereinthe base is attached to the cartridge casing body by screwing threads onthe base together with threads on the cartridge casing body.
 101. Themethod as set forth in claim 99, wherein the base is attached to thecartridge casing body by connecting a tongue and groove arrangementbetween attachable portions of the base and the cartridge casing body.102. The method as set forth in claim 99, wherein the base is attachedto the cartridge casing body by an interference fit.
 103. The method asset forth in claim 93, wherein the base is attached to the cartridgecasing body by adhesive joining.
 104. The method as set forth in claim93, wherein the base is attached to the cartridge casing body by heatbonding.
 105. The method as set forth in claim 93, wherein the base isattached to the cartridge casing body by ultrasonic welding.
 106. Amethod of making an ammunition article, comprising: molding plastic toform a molded plastic cartridge case body, the cartridge case bodyincluding a web dividing an internal volume of the body to define alower cavity for receiving a propellant and an upper cavity forreceiving a projectile, the web including an upwardly extending prong;and causing the upwardly extending prong to be received in acorresponding recess in a base of the projectile to fasten the body tothe projectile.
 107. The method as set forth in claim 106, wherein theprong is attached in the recess by an interference fit.
 108. The methodas set forth in claim 106, wherein the prong is attached in the recessby interlocking structures on the prong and the recess.
 109. The methodas set forth in claim 106, wherein the prong is attached in the recessby an adhesive.
 110. The method as set forth in claim 106, wherein theprong is attached in the recess by heat bonding.
 111. The method as setforth in claim 106, wherein the prong is attached in the recess byultrasonic welding.
 112. The method as set forth in claim 106, whereinthe plastic is molded around a core pull to form the lower cavity. 113.The method as set forth in claim 106, wherein the plastic is moldedaround at least a portion of a projectile to form the upper cavity andthe prong and to cause the prong to be received in the correspondingrecess.
 114. An ammunition article comprising: a projectile havingcannelure contours; and a molded cartridge casing body molded around atleast a portion of the projectile such that a portion of a wall of thecartridge casing body follows the cannelure contours of the projectile.115. The ammunition article as set forth in claim 114, wherein theportion of the wall has a substantially constant thickness.